2001 Yukon Fuel Tank Removal Questions

[JamesLond]

I wanted to make a single thread since annoyances keep coming up with this job.

Other thread

I've got the straps off and the rear of the tank is lowered, but now I can't get the front of the tank to come out. I spent over hour pulling on it to no avail.

I think it's because I haven't disconnected the 2 connectors on the pump, but it's a nightmare of deep caked on mud on them.


Now I tried to clean it up and squeeze the little tabs, but they don't depress. I figure mud managed to get caked underneath them and that's what's stopping me.

What's harder is that even if I can depress them, I can't contort myself in a way to push the connector off.

I notice there's similar connectors near the front of the tank and I think they are what connects to fuel pump. So, I think I might be able to remove them instead.

Unfortunately, there's a problem: I can squeeze the little tabs, but I can't fit another hand up to push the connector off.



And some guy in a video said tank removal is a 30 minute job....

 

[Blackcar]

If you're at a place where you can use a water hose, Crank pressure up just keep flushing top of tank until the mud is washed out. Good luck

 

[Fless]

If you're at a place where you can use a water hose, Crank pressure up just keep flushing top of tank until the mud is washed out. Good luck

Hose is a good idea if you aren't re-using the fuel pump or can clean out the electrical connectors before you return it to service.

Couple of ideas: I'm not sure if your tank is like mine, but my pressure and return lines were captured in snap clips on top of the tank. See photo below in the red circles. If the lines are out of those clips do you have some room to lower the tank a bit more? BTW, the tank has to move toward the back of the truck since the front of it goes above a crossmember.



As a last ditch effort (as I see it) the other thing you can do is cut off the fuel lines close to the pump. NAPA and others have the quick connects you need to replace them. IIRC they have an 18" pigtail of fuel line and a metal splice to connect to your existing (cut off) fuel line. @89Suburban recently patched his up with these pieces. If you need links we can find them for you. The pressure line should be 3/8" and the return 5/16".

EDIT: here's the 3/8" x 18" long quick connect pigtail with a splice connector. If you look on Amazon there are other splices that are somewhat like sharkbite connectors.

Dorman Products - 800-058

3/8 In. Quick Connector, Straight w/ 18 In. of 3/8 In. Nylon Tube and a Union

www.dormanproducts.com

 

[89Suburban]

Hose is a good idea if you aren't re-using the fuel pump or can clean out the electrical connectors before you return it to service.

Couple of ideas: I'm not sure if your tank is like mine, but my pressure and return lines were captured in snap clips on top of the tank. See photo below in the red circles. If the lines are out of those clips do you have some room to lower the tank a bit more? BTW, the tank has to move toward the back of the truck since the front of it goes above a crossmember.

View attachment 363225

As a last ditch effort (as I see it) the other thing you can do is cut off the fuel lines close to the pump. NAPA and others have the quick connects you need to replace them. IIRC they have an 18" pigtail of fuel line and a metal splice to connect to your existing (cut off) fuel line. @89Suburban recently patched his up with these pieces. If you need links we can find them for you. The pressure line should be 3/8" and the return 5/16".

EDIT: here's the 3/8" x 18" long pigtail with a splice connector. If you look on Amazon there are other splices that are somewhat like sharkbite connectors.

Dorman Products - 800-058

3/8 In. Quick Connector, Straight w/ 18 In. of 3/8 In. Nylon Tube and a Union

www.dormanproducts.com

That's the snap clips holding the lines onto the tank that were screwing me up trying to do it through the floor and getting the hoses to align with the pump. You can see the 3/8 line on the left in your pic is offset and there was an "S" bend in the factory line. I was able to make a loop of line around the pump head and back to line it up.

 

[JamesLond]

Hose is a good idea if you aren't re-using the fuel pump or can clean out the electrical connectors before you return it to service.

Couple of ideas: I'm not sure if your tank is like mine, but my pressure and return lines were captured in snap clips on top of the tank. See photo below in the red circles. If the lines are out of those clips do you have some room to lower the tank a bit more? BTW, the tank has to move toward the back of the truck since the front of it goes above a crossmember.

View attachment 363225

As a last ditch effort (as I see it) the other thing you can do is cut off the fuel lines close to the pump. NAPA and others have the quick connects you need to replace them. IIRC they have an 18" pigtail of fuel line and a metal splice to connect to your existing (cut off) fuel line. @89Suburban recently patched his up with these pieces. If you need links we can find them for you. The pressure line should be 3/8" and the return 5/16".

EDIT: here's the 3/8" x 18" long quick connect pigtail with a splice connector. If you look on Amazon there are other splices that are somewhat like sharkbite connectors.

Dorman Products - 800-058

3/8 In. Quick Connector, Straight w/ 18 In. of 3/8 In. Nylon Tube and a Union

www.dormanproducts.com

I'll take the last ditch connector idea if it comes to it.

Do you know if there's a similar product for the line with the squeeze connectors on the far right of your picture? I accidentally broke one when pulling it off the evap canister near the tank.

 

[Fless]

I'll take the last ditch connector idea if it comes to it.

Do you know if there's a similar product for the line with the squeeze connectors on the far right of your picture? I accidentally broke one when pulling it off the evap canister near the tank.

You broke the connector?

I don't, as I don't know the size of the line. Seems like it's fairly large, maybe 7/16" or 1/2" or even bigger.

 

[JamesLond]

OK, I got this stupid tank out. Thanks for the tips.

I plugged the fuel pump electrical connectors back in to avoid seepage and then sprayed the fuel line connectors with water. After that, I reached through the tire well and squeezed the connectors with long reach 90° bent nose pliers and was able to squeeze them successfully.

Afterwards, I squeezed the 2 connnectors at the front of the tank tighter and they came loose as well.

I then had to struggle getting the car up high enough to pulll the tank.

Thanks to members for the tips.

 

[Fless]

I forgot to say that hose grip pliers sometimes work.